Methods and systems for forming aligned holes

ABSTRACT

In one embodiment, a method for forming a pair of aligned holes is provided. The method comprises determining a diameter of a cleanup hole associated with a plurality of misaligned holes, in which the cleanup hole diameter may also correspond to a fastener diameter. Additionally, the tapered reamer is at least partially inserted into a gap defined by the plurality of misaligned holes. The tapered reamer has a longitudinal axis and may be configured such that the longitudinal axis aligns with a center of the cleanup hole when the tapered reamer is inserted into the gap defined by the plurality of misaligned holes. The plurality of misaligned holes may then be reamed with the tapered reamer to form the cleanup hole defined by the plurality of aligned holes having a same center and a same diameter.

BACKGROUND

1. Field

Devices and methods are disclosed for producing aligned holes frommisaligned holes. More particularly, systems and methods are disclosedfor determining the size of a fastener to be used and for producingaligned holes from the misaligned holes.

2. Background

When multiple objects are to be connected together, fasteners of varioussizes are commonly used. A circular hole is then drilled into eachobject, and ideally the objects are then placed next to one another suchthat the respective holes in the objects overlap each other andcircumferences of the holes align. For the purposes hereof, when two ormore such holes overlap with one another, the passageway through theholes is referred to as the gap. The virtual hole diameter of the gap isdefined as the bisector of the gap with the smallest length. As will beunderstood, it is the length of the smallest bisector through the gapwhich determines whether a given fastener will fit through the(mis)aligned holes. Presuming the holes in the objects align properly,the gap should have the same shape as either of the holes, such that thevirtual hole diameter of the gap is equal to the diameter of eitherhole. This is because with aligned holes, all bisectors of the gap havethe same length, which is equal to the diameter of either hole. Afastener which would fit through either of the holes should thereforefit through the gap defined by the aligned holes as well, so as tosecure the objects together.

However, a hole in one of the objects may not align properly with thecorresponding hole in the other object when the objects are broughttogether. Misalignment of the holes reduces the size of the resultinggap through the objects, and specifically results in a gap in which theshortest bisector is shorter than the diameter of either original hole.Thus, the misaligned holes result in a gap with a virtual hole diameterthat is smaller than the diameter of either hole and that couldpotentially be too small for the intended fastener to fit therethrough.As will be understood, a virtual hole that has a diameter equal to thevirtual hole diameter is theoretically the diameter of the largestfastener which would fit through a misaligned set of holes.

A common technique for correcting misaligned holes is to drill or ream acleanup hole through the misaligned holes, centered on one of themisaligned holes. A cleanup hole is preferably large enough in diameterthat all of the misaligned holes fit fully within the cleanup hole, suchthat nothing of the original misalignment remains. Once the cleanup holehas been created, a fastener—which may also have a larger diameter thanthe diameter of the originally intended fastener—is placed through thecleanup hole to secure the objects together.

Conventionally, cleanup holes are created on a trial-and-error basis.Progressively larger and larger diameter cutters are used toincrementally remove minimal amounts of material from the misalignedholes. Multiple sizes of go/no-go gages and visual inspection are usedto determine whether the newly-created cleanup hole meets fastenerinstallation requirements. This trial-and-error method involves anelement of subjectivity and is labor intensive. Special drill jigs areclamped to two or more adjacent holes or surfaces and are adjusted tocenter on the near-side misaligned hole. Not only is this process timeconsuming, but also requires a larger diameter hole to be produced toclean up the misaligned holes.

SUMMARY

In one embodiment, a method for forming a pair of aligned holes isprovided. The method comprises determining a diameter of a cleanup holeassociated with a plurality of misaligned holes, in which the cleanuphole diameter may also correspond to a fastener diameter. Additionally,a tapered reamer is at least partially inserted into a gap defined bythe plurality of misaligned holes. The tapered reamer has a longitudinalaxis and may be configured such that the longitudinal axis aligns with acenter of the cleanup hole when the tapered reamer is inserted into thegap defined by the plurality of misaligned holes. The plurality ofmisaligned holes may then be reamed with the tapered reamer to form thecleanup hole defined by the plurality of aligned holes having a samecenter and a same diameter.

In another embodiment, a method for forming a pair of aligned holes isprovided. The method comprises inserting a step gage into a gap definedby misaligned holes. The step gage may include at least a first sectionhaving a first diameter and a second section having a second diametersmaller than the first diameter. The first diameter may correspond to afirst cleanup hole diameter and the second diameter may correspond to asecond cleanup hole diameter larger than the first cleanup holediameter. When it is found that the first section fit through the gap,it is determined that the virtual hole diameter of the misaligned holescorresponds to a first standard fastener diameter. A first standardfastener has the first standard diameter fastener. When it is found thefirst section does not fit through the gap and the second section doesfit through the gap, it is determined that the virtual hole diameter ofthe gap is smaller than the first standard fastener diameter. A taperedreamer is used to form a second cleanup hole centered on a virtual holeassociated with the virtual hole diameter, in which the diameter of thesecond cleanup hole allows a first oversized fastener to be insertedthrough the second cleanup hole.

In another embodiment, a system for forming aligned holes is provided.The system may comprise a step gage configured to be inserted through agap defined by misaligned holes to determine a diameter of a cleanuphole. The step gage may include a first section having a first diametercorresponding to a first cleanup hole diameter, and a second sectionhaving a second diameter corresponding to a second cleanup hole diameterlarger than the first cleanup hole diameter. The first and secondsections of the step gage may be connected and may extend in seriesalong a longitudinal axis of the step gage. The system may also comprisea tapered reamer having a longitudinal axis and configured such that thelongitudinal axis aligns with a center of the cleanup hole when thetapered reamer is at least partially inserted into the gap defined bythe pair of misaligned holes.

In one embodiment, a step gage comprises a first section having adiameter equal to about twice the diameter of an intended hole, minus adiameter of a first cleanup hole. The step gage also comprises a secondsection having a diameter equal to about twice the diameter of theintended hole, minus the diameter of a second cleanup hole which islarger than the diameter of the first cleanup hole. The first sectionand the second section are connected and extend in series along alongitudinal axis of the step gage.

The features, functions, and advantages that have been discussed can beachieved independently in various embodiments or may be combined in yetother embodiments further details of which can be seen with reference tothe following description and drawings.

These and other advantageous features will be in part apparent and inpart pointed out herein below.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding, reference may be made to the accompanyingdrawings in which:

FIG. 1A is a top plan view of aligned holes in overlapping objects.

FIG. 1B-1D illustrate examples of misaligned holes, in which themisalignment increases from FIG. 1B through FIG. 1D.

FIG. 2 illustrates a side elevation view of one example of a step gageaccording to an embodiment.

FIGS. 3A-3D illustrate side elevation views of the step gage of FIG. 2being inserted into the holes of FIGS. 1A-1D.

FIG. 4 illustrates a side elevation view of one example of a taperedreamer according to an embodiment.

FIG. 5A is a graph showing the relationship between the length of areamer's taper and the degrees of taper.

FIG. 5B is a graph showing the relationship between the positionalaccuracy of a tapered reamer and the degrees of taper.

FIG. 6 illustrates a flow chart for using a step gage and taperedreamer.

While various modifications and alternative forms are envisioned,specific embodiments thereof are shown by way of example in the drawingsand will herein be described in detail. It should be understood,however, that the drawings and detailed description presented herein arenot intended to limit to the particular embodiment disclosed, but on thecontrary, the intention is to cover all modifications, equivalents, andalternatives falling within the spirit and scope hereof as defined bythe appended claims.

DESCRIPTION

According to one embodiment, various views are illustrated in FIGS. 1-6and like reference numerals are being used consistently throughout torefer to like and corresponding parts for all of the various views andfigures of the drawings. Also, please note that the first digit(s) ofthe reference number for a given item or part should correspond to thefigure number in which the item or part is first identified.

Apparatuses and methods for creating aligned holes are provided. A stepgage may have at least two steps of different diameters. These differentdiameters are sized and shaped to inform the user as to theappropriately sized cleanup hole needed to fully clean up the gapremaining between overlapping holes when such overlapping holes aremisaligned. Once a cleanup hole size has been determined, a taperedreamer may be used which can be manually aligned on the misalignedholes, rather than on the near-side misaligned hole. The tapered reamereffectively aligns itself during use on the misaligned holes. Thus, ajig need not be used, and the resulting cleanup hole can be smaller thancleanup holes made using conventional processes. Forming the cleanuphole through the misaligned holes is also referred to herein as“cleaning up” the misaligned holes, which means formingconcentrically-aligned holes having the same center and diameter throughthe existing misaligned holes.

One embodiment described herein teaches a step gage for determining adiameter of an appropriate cleanup hole. The details of the variousembodiments can be better understood by referring to the figures of thedrawing. Referring to FIG. 1A, two objects, such as plates 105, 110, areshown. Each plate 105, 110 includes a hole 107, 112 respectively,extending therethrough. Holes 107, 112 have a diameter approximatelyequal to an intended hole diameter (IHD). As shown in FIG. 1A, theplates 105, 110 have been brought together such that holes 107, 112 forma gap 100A therethrough.

Both of holes 107, 112 have a diameter approximately equal to the IHD.Each such hole 107, 112 is sized to receive a fastener of apredetermined diameter therethrough. As will be understood, if either ofthe respective holes 107, 112 in the two plates 105, 110 have exactlythe same diameter as the intended fastener, the fastener may not fitthrough gap 100A even if the two holes 107, 112 are properly aligned.Therefore, the holes 107, 112 in the respective plates 105, 110 aretypically drilled to have a diameter which is slightly larger than thatof the intended fastener, although not so much larger that too muchspace would remain even with the intended fastener inserted therein.This is referred to as the least material condition of the holes 107,112. The least material condition of these holes is therefore thecircumstance in which each hole 107, 112 has the largest diameter withintolerance, such that the least material remains within tolerance.

As seen in FIG. 1A, the holes 107, 112 in the two plates 105, 110 areproperly aligned, such that the hole 112 is not discretely visible belowhole 107. All bisectors through gap 100A have the same length, which isequal to the diameter of holes 107, 112. Therefore, the gap 100A has avirtual hole diameter (VHD) equal to the diameter of the holes 107, 112.The creation of a cleanup hole may therefore be inappropriate. However,for the purposes hereof, the virtual hole diameter (VHD) and thediameter of the holes 107, 112 in FIG. 1A is equal to a first cleanuphole diameter.

In FIGS. 1B through 1D, the plates 105, 110 have been excluded for easeof reference. FIG. 1B illustrates holes 107, 112 as being slightlymisaligned, such that the geometric center of hole 107 is spaced apartfrom the geometric center of hole 112. Unlike gap 100A in FIG. 1A, gap100B in FIG. 1B has a shortest bisector, which is labeled VHD. As can beseen, the misalignment of the holes 107, 112 causes the VHD of theresulting gap 100B to be smaller than the diameter of either of holes107, 112, (and thus smaller than the diameter hole associated with anintended fastener). A virtual hole 120B having the VHD of gap 100B isshown in phantom in FIG. 1B. This virtual hole 120B has a diameter(again, VHD) of the largest diametered circle which will fit within gap100B.

Due to the misalignment of the holes 107, 112, a second cleanup hole115B (also shown in phantom in FIG. 1B) may be created through theplates 105, 110 (not shown). Such second cleanup hole 115B preferablyfully encompasses the holes 107, 112. A cleanup hole which does notfully encompass the holes 107, 112 is possible, but would result in alower precision fit between the cleanup hole and the fastener.

FIG. 1C illustrates holes 107, 112 as being more misaligned than thoseshown in FIG. 1B, such that the geometric center of hole 107 is spacedfarther from the geometric center of hole 112 than in FIG. 1B. Like gap100B in FIG. 1B, gap 100C in FIG. 1C has a shortest bisector, which isagain labeled VHD. The VHD of gap 100C is shorter than the VHD of gap100B, because the misalignment of holes 107, 112 is greater in FIG. 1Cthan in FIG. 1B. As can be seen, the increased misalignment of the holes107, 112 again causes the VHD of the resulting gap 100C to be smallerthan the diameter of either of holes 107, 112. A virtual hole 120Chaving the VHD of gap 100C is shown in phantom in FIG. 1C. This virtualhole 120C has a diameter (again, VHD) of the largest diametered circlewhich will fit within gap 100C.

Due to the increased misalignment of the holes 107, 112 in FIG. 1C, athird cleanup hole 115C (also shown in phantom in FIG. 1C) may becreated through the plates 105, 110 (not shown). Such third cleanup hole115C preferably fully encompasses the holes 107, 112, and wouldtherefore be larger in diameter than second cleanup hole 115B, due tothe increased misalignment of holes 107, 112.

FIG. 1D illustrates holes 107, 112 as being more even more misalignedthan those shown in FIG. 1C, such that the geometric center of hole 107is spaced even farther from the geometric center of hole 112 than inFIG. 1C. Like gap 100C in FIG. 1C, gap 100D in FIG. 1D has a shortestbisector, which is again labeled VHD. The VHD of gap 100D is shorterthan the VHD of gap 100C, because the misalignment of holes 107, 112 isgreater in FIG. 1D than in FIG. 1C. As can be seen, the increasedmisalignment of the holes 107, 112 again causes the VHD of the resultinggap 100D to be smaller than the diameter of either of holes 107, 112. Avirtual hole 120D having the VHD of gap 100D is shown in phantom in FIG.1D. This virtual hole 120D has a diameter (again, VHD) of the largestdiametered circle which will fit within gap 100D.

Due to the additionally increased misalignment of the holes 107, 112 inFIG. 1D, a fourth cleanup hole 115D (also shown in phantom in FIG. 1D)may be created through the plates 105, 110 (not shown). Such fourthcleanup hole 115D preferably fully encompasses the holes 107, 112, andwould therefore be larger in diameter than the third cleanup hole 115C,due to the increased misalignment of holes 107, 112.

FIG. 2 illustrates an example step gage 200 in accordance with anembodiment. As shown, step gage 200 includes four sections or steps: afirst section 205 having a first diameter 207, a second section 210having a second diameter 212, a third section 215 having a thirddiameter 217, and a fourth section 220 having a fourth diameter 222.These four sections 205-220 extend in series along the longitudinal axis230 of the step gage 200. Sections 205-220 may be integrally formed ofany suitable material including (but not limited to) metal, plastic,wood, etc. Alternatively, sections 205-220 may be formed separately andthen connected together, for example by (but not limited to) welding,adhesive, etc. The diameters 207-222 of these four sections 205-220 areselected in order to inform a technician as to the whether the intendedfastener size will fit within a gap defined by holes 107, 112. If theintended size fastener will not fit within the gap, the step gage 200will indicate the appropriate size cleanup hole diameter which willfully encompass both misaligned holes (105B-105D, 110B-110D) and whichwill accept a fastener therethrough.

When attempting to determine the diameter of an appropriate cleanuphole, choices of the technician drilling the cleanup hole are somewhatconstrained by the available fastener sizes. As will be understood, itmakes little sense to create a cleanup hole which is too small for agiven stocked fastener, but too large for the next larger sizedfastener. The technician instead preferably determines the smallest sizecleanup hole which will fully encompass the two misaligned holes 107,112, but which also has an appropriate diameter for accepting thereinone of the available fasteners. Of course, technicians generally stockstandard-sized fasteners. For example, technicians often stock standardfastener sizes such as ¼ inch, 5/16 inch, ⅜ inch, 7 mm, 8 mm, 10 mm, 12mm, etc. Many technicians also stock so-called oversized fasteners whichare sized between the standard size fasteners. Thus, for example,between a ¼ inch (0.25 inch) fastener and a 5/16 inch (0.3125 inch)fastener, a manufacturer may stock a first-oversized fastener sized0.2656 inch and a second-oversized fastener sized 0.2812 inch.0.25<0.2656<0.2812<0.3125. This gives the technician additional optionsfor cleanup hole sizes. As will be understood, these numbers are merelyexemplary. Technicians may stock more or fewer oversized fasteners, ornone at all.

The first through fourth sections 205-220 of step gage 200 havediameters 207, 212, 217, 222 with sizes selected to specifically informthe user as to the appropriate cleanup hole diameter. This isaccomplished according to the following formula: the virtual holediameter of the gap is equal to double the diameter of the intended hole(IHD), minus the diameter of the cleanup hole (CUD), which can bewritten as: VHD=(2×IHD)−CUD. As discussed above, the cleanup holediameter (CUD) is the diameter of a cleanup hole which would produceconcentrically-aligned holes have the same diameter. In the aboveformula, the intended hole diameter (IHD) can be the actual diameter ofan intended fastener (e.g., 0.25 for a ¼ inch diameter fastener) or theleast material condition diameter (e.g., 0.254 inches for a ¼ inchdiameter fastener).

As noted above, there is a set of cleanup hole diameters correspondingto the diameters of the available fasteners. This set of cleanup holediameters is, thus, a set of predetermined hole diameters that arepreferred by the technician because holes having these diameters willaccept available fasteners therein. One of these predetermined cleanuphole diameters (CUD) can be inserted into the above formula, along withthe intended hole diameter (IHD). The resulting number will be equal tothe virtual hole diameter (VHD) of the misaligned holes which would havea cleanup hole having the CUD value used in the formula. A step (alsoreferred to as a “section”) of gage 200 may then be created with thedetermined virtual hole diameter. If that step fits within the gapdefined by a misaligned set of holes 107, 112, the technician knows thata cleanup hole having the CUD used in the equation for that step willclean up the misaligned holes.

The above-discussed non-limiting example of a first standard fastenerhaving a first fastener diameter (e.g., 0.25 inches) will be used tofurther clarify the use of the above formula. The first standardfastener is associated with a hole having a least material conditiondiameter (e.g., 0.254 inches). For a situation as shown in FIG. 1A inwhich the holes 107, 112 are properly aligned, no cleanup hole is formedbecause the gap resulting from the overlapping holes 107, 112 has afirst VHD that is equal to the least material condition diameterassociated with the first standard fastener. In other words, the firstcleanup hole diameter is already equal to the VHD. The first section 205of step gage 200 would therefore simply have a diameter 207 of about theVHD. Thus, if the first section 205 of step gage 200 fits within the gap100A created by aligned holes 107, 112 as shown in FIG. 3A, then thefirst standard fastener should fit through the gap 100A. Another way toconfirm this, of course, is simply insert the first standard fastenerthrough the gap 100A.

A first oversized fastener has a second fastener diameter that is largerthan the first fastener diameter (e.g., a diameter of 0.2616 inches),and a second cleanup hole diameter (e.g., 0.2656 inches) is associatedwith the first oversized fastener. The formula results in a firstvirtual hole diameter (e.g., (2×0.254)−0.2656=0.2424 inches). The IHDhas not changed from the example above, because the IHD is equal to theoriginally intended hole diameter of holes 107, 112. Thus, the diameter212 of the second section 210 of step gage 200 is equal to the firstvirtual hole diameter (e.g., 0.2424 inches). If the second section 210of step gage 200 fits into the gap 100B defined by the misaligned holes107, 112 but the first section 205 does not, as shown in FIG. 3B, thegage 200 indicates that a cleanup hole having the second cleanup holediameter will accept the first oversized fastener therein.

A second oversized fastener has a third fastener diameter larger thanthe second fastener diameter (e.g., 0.2772 inches), and a third cleanuphole diameter (e.g., 0.2812 inches) is associated with the secondoversized fastener. The formula results in a second virtual holediameter (e.g., (2×0.254)−0.2812=0.2268 inches). Thus, the diameter 217of the third section 215 of step gage 200 is equal to the second virtualhole diameter (e.g., 0.2268 inches). If the third section 215 of stepgage 200 fits into the gap 100C defined by the misaligned holes 107, 112but the first and second sections 205, 210 do not, as shown in FIG. 3C,the gage 200 indicates that a cleanup hole having the third cleanup holediameter will accept the second oversized fastener.

A second standard fastener has a fourth fastener diameter larger thanthe third fastener diameter (e.g., 0.3125 inches), and a fourth cleanuphole diameter (e.g., 0.3165) inches is associated with the secondstandard fastener. The formula results in a third virtual hole diameter(e.g., (2×0.254)−0.3125=0.1955 inches). Thus, the diameter 222 of thefourth section 220 of step gage 200 is equal to the third virtual holediameter (e.g., 0.1955 inches). If the fourth section 220 of step gage200 fits into the gap 100D defined by the misaligned holes 105D, 110Dbut the first through third sections 205-215 do not, as shown in FIG.3D, the gage 200 indicates that a cleanup hole having the fourth cleanuphole diameter will accept the second standard fastener.

As will be understood, the same formula can be used with variousfastener diameters and various cleanup hole diameters (which correspondto various oversized/standard diameter fasteners) to determine theappropriate diameter for a given step on gage 200. When two oversizedfasteners are available with diameters between two standard diameterfasteners, a step gage 200 as shown in FIGS. 2 and 3A-3D can be createdwith four steps: a first step 205 corresponding to the first standardfastener, a second step 210 corresponding to the first oversizefastener, a third step 215 corresponding to the second oversizedfastener, and a fourth step 220 corresponding to the second standardfastener.

It is noted that fewer or more steps could be included in the step gage200. For example, when no oversized fasteners are available, a two-stepgage having one step corresponding to the first standard fastener andanother step corresponding to the second standard fastener. Further,when only a single oversized fastener is available, a three-step gagemay be used. Alternatively, regardless of the number of oversizedfasteners available, step gages with any desired number of steps can beused. The four-step gage 200 shown in FIG. 2 and the specific diametersdiscussed above are therefore merely exemplary, and should be considereda non-limiting example.

Once the appropriate cleanup hole diameter is determined, a device suchas reamer 400 shown in FIG. 4 may be used to create the cleanup hole. Asshown, reamer 400 is a tapered reamer 400, and includes a shaft 402.Shaft 402 may include a chuck shaft 405 and a bushing shaft 410. Taperedreamer 400 also includes a lead portion 412 extending from the shaft402. The lead portion 412 includes a final diameter section 415 that hasa final diameter 417. Extending from the final diameter section 415 is atapered diameter section 420. The tapered diameter section 420 includesa proximal end 422 abutting the final diameter section 415 and a distalend 424 opposite the proximal end 422. The proximal end 422 has thefinal diameter 417, and the distal end 424 has a beginning diameter 425.Accordingly, the tapered diameter section 420 decreases in diameter fromthe final diameter 417 to the beginning diameter 425 from the proximalend 422 toward the distal end 424. The lead portion 412 preferablyincludes one or more flutes 430. Flutes 430 may be straight, helical, orany other suitable configuration.

Preferably, the tapered diameter section 420 tapers from the finaldiameter 417 to the beginning diameter 425 at a predetermined angle 430.The predetermined angle 430 may be between about 0.5 degrees to 1 degreeper side (i.e., half-angle), which gives about 1-2 degrees angleoverall. When manually positioned at the center of a virtual hole 120B,120C, 120D the angle 430 of tapered diameter section 420 allows thereamer 400 to remain at approximately the center of the virtual hole120B, 120C, 120D. This is referred to as positional accuracy. The angle430 is selected to avoid using a jig to position and hold the reamerappropriately. Further, by centering on the virtual hole 120B, 120C,120D, a smaller diameter cleanup hole can be created, as compared tocentering a reamer on only one of the holes 107, 112 (which alsogenerally entails the use of a jig).

The angle 430 is derived as a balance between competing factors. On onehand, a more gradual taper (e.g., a small value of angle 430) would leadto a tapered diameter section 420 having a greater length than a lengthof section 420 having a larger angle 430. On the other hand, the angle430 of the tapered diameter section 420 guides the tapered reamer 400through the center of the virtual hole 120B, 120C, 120D and gap 100B,100C, 100D during reaming. A less gradual taper (e.g., a larger value ofangle 430) may increase error in the positional accuracy of the taperedreamer 400 (i.e., the reamer 400 may stray from the center of thevirtual hole 120B, 120C, 120D during reaming). Indeed, it has been foundthat a larger value of angle 430 results in a tapered reamer 400 whichmay not remain centered on the center of the virtual hole 120B, 120C,120D during reaming. Charts illustrated in FIGS. 5A and 5B provideexemplary relationships based on the angle of the tapered diametersection 420 that can be used select the angle of taper.

FIG. 5A illustrates the relationship between the angle (in degrees) oftaper of the tapered diameter section 420 as compared to the length oftapered diameter second 420, when the each of the objects being securedtogether (e.g. plates 105, 110) has a thickness “t” of 0.1 inches. Ascan be seen, below about 0.5 degrees of taper, the length of the tapereddiameter section 420 increases exponentially. Therefore, degrees oftaper below about 0.5 degrees may be undesirable in some applications.FIG. 5B illustrates the relationship between the angle (in degrees) oftaper of the tapered diameter section 420 as compared to the positionalaccuracy (in inches) of the tapered reamer 400 (in which lower numbersare more accurate). As can be seen, above about 1 degrees of taper, thepositional accuracy of the reamer 400 may not have the accuracyspecified for a high-accuracy manufacturing process, such asmanufacturing machinery. Therefore, an angle of taper below 1half-degree would be more desirable for the high-accuracy manufacturingprocess.

FIG. 6 illustrates a flow chart of a method 600 for using the step gage200 and tapered reamer 400, according to an example embodiment. At step605, the step gage 200 is inserted into the gap, such as gap 100A-100Ddefined by at least two overlapping holes, such as holes 107 and 112. Atstep 610, a determination is made as to whether the first section 205 ofthe gage 200 fits within the gap. If the first section 205 fits throughthe gap, at step 615, the first standard fastener may be inserted intothe gap. If the first section 205 does not fit through the gap, at step620, a determination is made as to whether the second section 210 of thegage 200 fits within the gap. If the second section 210 fits through thegap, at step 625, the tapered reamer 400 is used to produce a cleanuphole having the second cleanup hole diameter such that the cleanup holeaccepts the first oversized fastener having the second fastenerdiameter. The tapered diameter section 420 is inserted at leastpartially into the gap, and the misaligned holes are cleaned up to thediameter of the final diameter section 415, which is approximately equalto the second cleanup hole diameter. At step 630, the correspondingfirst oversized fastener can be inserted through the cleanup hole.

At step 620, if the second section 210 does not fit through the gap, adetermination is made at step 635 as to whether the third section 215 ofthe gage 200 fits within the gap. If the third section 215 fits throughthe gap, at step 640, the tapered reamer 400 is used to produce aninitial cleanup hole having the second cleanup hole diameter such thatthe initial cleanup hole would accept the first oversized fastener. Atstep 645, a standard reamer is then used to enlarge the initial cleanuphole to a final cleanup hole having the third cleanup hole diameter toaccept the second oversized fastener having the third fastener diameter.A standard reamer may be a reamer without a tapered diameter section, inwhich the lead portion has a substantially uniform diameter throughoutits length. After the tapered reamer 400 has produced an initial cleanuphole at step 640, a standard reamer may be used with acceptablepositional accuracy. More specifically, the tapered reamer 400 producesan initial cleanup hole having a center aligned with a center of thevirtual hole that was associated with the resulting gap. Accordingly,the standard reamer may remain centered on the center of the initialcleanup hole formed by the tapered reamer 400, and the use of a jig toposition and hold the standard reamer on the center of the initialcleanup hole can be avoided. At step 650, the second oversized fastenercan be inserted through the final cleanup hole.

At step 635, if the third section 215 does not fit though the gap, adetermination is made at step 655 as to whether the fourth section 220of the gage 200 fits within the gap. If the fourth section 220 can beinserted through the gap, at step 660, a jig and reamer (or otherdrilling tool, as appropriate) for producing a hole having the fourthcleanup hole diameter for the accepting next standard sized fastener areutilized. The jig and reamer of step 660 may be utilized when thevirtual hole has a sufficiently small diameter that the tapered diametersection 420 of tapered reamer 400 may not properly guide the taperedreamer 400 through the center of a virtual hole with. At step 660, ifthe virtual hole has a diameter which is large enough to allow use ofthe tapered reamer 400 without a jig, the fourth cleanup hole may beproduced according to steps similar to steps 640 and 645, with at leastone progressively larger reamer used after the tapered reamer 400 hasbeen used. If, at step 655, the fourth section 220 does not fit withinthe gap, at step 665 the misaligned holes are flagged for furtherprocessing.

As will be understood, method 600 specifically relates to a four-stepgage 200 that can be used when two oversized fasteners and two standardfasteners are available. A modified methodology would apply to a stepgage with a different number of sections. For example, when only asingle oversized fastener and two standard fasteners are available, athree step gage may be used and method steps 635-650 may be omitted.Additional method steps may be added for step gages with additionalsteps.

As is evident from the foregoing description, certain aspects of thepresent implementation are not limited by the particular details of theexamples illustrated herein, and it is therefore contemplated that othermodifications and applications, or equivalents thereof, will occur tothose skilled in the art. It is accordingly intended that the claimscover such modifications and applications that do not depart from thespirit and scope of the present implementation. Accordingly, thespecification and drawings are to be regarded in an illustrative ratherthan a restrictive sense.

The steps of the methods described herein need not be executed in theorder described, or in any particular order. Moreover, variousactivities described with respect to the methods identified herein canbe executed in serial or parallel fashion. In the foregoing DetailedDescription, it can be seen that various features are grouped togetherin a single embodiment for the purpose of streamlining the disclosure.This method of disclosure is not to be interpreted as reflecting anintention that the claimed embodiments require more features than areexpressly recited in each claim. Rather, as the following claimsreflect, inventive subject matter may lie in less than all features of asingle disclosed embodiment. Thus, the following claims are herebyincorporated into the Detailed Description, with each claim standing onits own as a separate embodiment.

The various examples shown above illustrate a step gage, a taperedreamer, and a method for using same. A user may choose any of the aboveembodiments, or an equivalent or variation thereof, depending upon thedesired application. In this regard, it is recognized that various formsof the subject step gage and tapered reamer could be utilized withoutdeparting from the spirit and scope hereof.

Further, the disclosure comprises embodiments according to the followingclauses:

Clause 1. A method for forming a plurality of aligned holes, the methodcomprising:

-   determining a diameter of a cleanup hole associated with a plurality    of misaligned holes, the cleanup hole diameter corresponding to a    fastener diameter;-   at least partially inserting a tapered reamer into a gap defined by    the plurality of misaligned holes, the tapered reamer having a    longitudinal axis and configured such that the longitudinal axis    aligns with a center of the cleanup hole when the tapered reamer is    inserted into the gap defined by the plurality of misaligned holes;-   reaming the plurality of misaligned holes with the tapered reamer to    form the cleanup hole defined by the plurality of aligned holes    having a same center and a same diameter.

Clause 2. The method of clause 1, wherein the step of determining adiameter of a cleanup hole further includes the steps of:

-   inserting a step gage into the gap defined by the plurality of    misaligned holes, the step gage including at least a first section    having a first diameter and a second section having a second    diameter smaller than the first diameter, the first diameter    corresponding to a first cleanup hole diameter and the second    diameter corresponding to a second cleanup hole diameter larger than    the first cleanup hole diameter; and-   determining the diameter of the cleanup hole based on whether one or    more of the first and second sections fit within the gap.

Clause 3. The method of clause 2, wherein the step of reaming theplurality of misaligned holes further comprises reaming the plurality ofmisaligned holes to form the cleanup hole having a first cleanup holediameter, wherein the first cleanup hole diameter allows a firststandard fastener to be inserted through the cleanup hole.

Clause 4. The method of clause 2, wherein the step of reaming theplurality of misaligned holes further comprises reaming the plurality ofmisaligned holes to form the cleanup hole having a second cleanup holediameter, wherein the second cleanup hole diameter allows a firstoversized fastener to be inserted through the cleanup hole.

Clause 5. A method for forming aligned holes, the method comprising:

-   inserting a step gage into a gap defined by misaligned holes, the    step gage including at least a first section having a first diameter    and a second section having a second diameter smaller than the first    diameter, the first diameter corresponding to a first cleanup hole    diameter and the second diameter corresponding to a second cleanup    hole diameter larger than the first cleanup hole diameter;-   when the first section fits through the gap, determining that a    virtual hole diameter of the misaligned holes corresponds to a first    standard fastener diameter, wherein a first standard fastener has    the first standard fastener diameter; and-   when the first section does not fit through the gap and the second    section does fit through the gap:-   determining that the virtual hole diameter of the gap is smaller    than the first standard fastener diameter; and-   using a tapered reamer to form a second cleanup hole centered on a    virtual hole associated with the virtual hole diameter, wherein the    diameter of the second cleanup hole allows a first oversized    fastener to be inserted through the second cleanup hole.

Clause 6. The method of clause 5, wherein the step gage further includesa third section having a third diameter smaller than the second diameterand a fourth section having a fourth diameter smaller than the thirddiameter, the third diameter corresponding to a third cleanup holediameter larger than the second cleanup hole diameter and the fourthdiameter corresponding to a fourth cleanup hole diameter larger than thethird cleanup hole diameter, the method further comprising:

-   when the third section fits through the gap and the first and second    sections do not fit through the gap:-   determining that the virtual hole diameter of the gap defined by the    misaligned holes corresponds to a third cleanup hole diameter;-   using the tapered reamer to form an initial cleanup hole having the    diameter of the second cleanup hole centered on the virtual hole    associated with the virtual hole diameter; and-   using a standard reamer to form a third cleanup hole having the    third cleanup hole diameter centered on the geometric center of the    initial cleanup hole, wherein the third cleanup hole diameter allows    a second oversized fastener to be inserted through the third cleanup    hole; and-   when the fourth section fits through the gap and the first, second,    and third sections do not fit through the gap:-   determining that the virtual hole diameter of the gap corresponds to    a fourth cleanup hole diameter;-   determining that a fourth cleanup hole having the fourth cleanup    hole diameter centered on the virtual hole associated with the    virtual hole diameter is appropriate, wherein the fourth cleanup    hole diameter allows a second standard fastener to be inserted    through the fourth cleanup hole.

Clause 7. The method of clause 6, wherein upon determining that thefourth section fits within the gap and that the first, second, and thirdsections do not:

-   forming the fourth cleanup hole centered on the virtual hole    associated with the virtual hole diameter.

Clause 8. The method of clause 7, wherein the step of forming the fourthcleanup hole further comprises the steps of:

-   using the tapered reamer to form an initial cleanup hole having the    diameter of the second cleanup hole centered on the virtual hole    associated with the virtual hole diameter;-   using the first standard reamer to form the third cleanup hole    having the third cleanup hole diameter centered on the geometric    center of the initial cleanup hole-   using a second standard reamer to form the fourth cleanup hole    having the fourth cleanup hole diameter centered on the geometric    center of the third cleanup hole.

Clause 9. The method of clause 7, wherein the step of forming the fourthcleanup hole further comprises the step of:

-   using a second standard reamer and a jig to form the fourth cleanup    hole having the fourth cleanup hole diameter centered on the virtual    hole associated with the virtual hole diameter.

Clause 10. The method of clause 5, wherein the step of using a taperedreamer further comprises the step of centering the reamer on themisaligned holes without the use of a jig.

Clause 11. A system for forming aligned holes, the system comprising:

-   a step gage configured to be inserted through a gap defined by    misaligned holes to determine a diameter of a cleanup hole, said    step gage comprising:-   a first section having a first diameter corresponding to a first    cleanup hole diameter; and-   a second section having a second diameter corresponding to a second    cleanup hole diameter larger than the first cleanup hole diameter,    the first and second sections being connected and extend in series    along a longitudinal axis of the step gage; and-   a tapered reamer having a longitudinal axis and configured such that    the longitudinal axis aligns with a center of the cleanup hole when    the tapered reamer is at least partially inserted into the gap    defined by the misaligned holes.

Clause 12. The system of clause 11, wherein the step gage furthercomprises at least a third section and a fourth section which correspondto a third cleanup hole diameter and a fourth cleanup hole diameter,respectively.

Clause 13. The system of clause 11, wherein said tapered reamercomprises a tapered diameter section having a beginning diameter whichis smaller than a final diameter, the tapered diameter section taperingfrom the final diameter to the beginning diameter at an angle of betweenabout 0.5 degrees and about 1.0 degrees per side.

Clause 14. A step gage comprising:

-   a first section having a diameter equal to about twice a diameter of    an intended hole, minus a diameter of a first cleanup hole; and-   a second section having a diameter equal to about twice the diameter    of the intended hole, minus a diameter of a second cleanup hole    which is larger than the diameter of the first cleanup hole, wherein    said first section and said second section are connected and extend    in series along a longitudinal axis of the step gage.

Clause 15. The step gage of clause 14, wherein the diameter of the firstcleanup hole allows a first standard fastener to be inserted through thefirst cleanup hole.

Clause 16. The step gage of clause 14, wherein the diameter of thesecond cleanup hole allows a first oversized fastener to be insertedthrough the second cleanup hole.

Clause 17. The step gage of clause 14, further comprising:

-   a third section having a diameter equal to about twice the diameter    of the intended hole, minus a diameter of a third cleanup hole which    is larger than the diameter of the second cleanup hole; and-   a fourth section having a diameter equal to about twice the diameter    of the intended hole, minus a diameter of a fourth cleanup hole    which is larger than the third cleanup hole; and-   wherein the first, second, third, and fourth sections are connected    and extend in series along the longitudinal axis of the step gage.

Clause 18. The step gage of clause 17, wherein:

-   the diameter of the intended hole is approximately equal to the    diameter of the first cleanup hole;-   the diameter of the second cleanup hole allows a first oversized    fastener to be inserted through the second cleanup hole;-   the diameter of the third cleanup hole allows a second oversized    fastener to be inserted through the third cleanup hole-   the diameter of the fourth cleanup hole allows a second standard    fastener to be inserted through the fourth cleanup hole

Clause 19. The step gage of clause 17, wherein the first section ispositioned at a first end of the step gage, the second section ispositioned between the first and third sections, the third section ispositioned between the second and fourth sections, and the fourthsection is positioned at a second opposing end of the step gage.

Clause 20. The step gage of clause 14, wherein the first and secondsections are integrally formed.

Clause 21. A system for forming aligned holes, the system comprising:

-   a step gage comprising at least first and second sections of    differing diameters, wherein each diameter of each section    corresponds to a respective cleanup hole diameter; and-   a tapered reamer comprising a tapered diameter section that tapers    from a final diameter to a beginning diameter at angle between about    0.5 degrees and 1 degree per side, wherein said final diameter is    approximately equal to the diameter of a second cleanup hole;-   wherein said step gage is configured for insertion into a gap    defined by misaligned holes for determining an appropriate cleanup    hole diameter based on which of the first and second sections fits    through the gap; and-   wherein the tapered reamer is configured to form a cleanup hole    having the diameter of the second cleanup hole.

Clause 22. The system of clause 21, wherein the step gage comprises atleast a third section and a fourth section which correspond to a thirdcleanup hole diameter and a fourth cleanup hole diameter, respectively.

As is evident from the foregoing description, certain aspects hereof arenot limited by the particular details of the examples illustratedherein, and it is therefore contemplated that other modifications andapplications, or equivalents thereof, will occur to those skilled in theart. It is accordingly intended that the claims shall cover all suchmodifications and applications that do not depart from the spirit andscope hereof.

Other aspects, objects and advantages hereof can be obtained from astudy of the drawings, the disclosure and the appended claims.

What is claimed is:
 1. A method for forming a plurality of alignedholes, the method comprising: determining a diameter of a cleanup holeassociated with a plurality of misaligned holes, the cleanup holediameter corresponding to a fastener diameter; at least partiallyinserting a tapered reamer into a gap defined by the plurality ofmisaligned holes, the tapered reamer having a longitudinal axis andconfigured such that the longitudinal axis aligns with a center of thecleanup hole when the tapered reamer is inserted into the gap defined bythe plurality of misaligned holes; reaming the plurality of misalignedholes with the tapered reamer to form the cleanup hole defined by theplurality of aligned holes having a same center and a same diameter. 2.The method of claim 1, wherein the step of determining a diameter of acleanup hole further includes the steps of: inserting a step gage intothe gap defined by the plurality of misaligned holes, the step gageincluding at least a first section having a first diameter and a secondsection having a second diameter smaller than the first diameter, thefirst diameter corresponding to a first cleanup hole diameter and thesecond diameter corresponding to a second cleanup hole diameter largerthan the first cleanup hole diameter; and determining the diameter ofthe cleanup hole based on whether one or more of the first and secondsections fit within the gap.
 3. The method of claim 2, wherein the stepof reaming the plurality of misaligned holes further comprises reamingthe plurality of misaligned holes to form the cleanup hole having afirst cleanup hole diameter, wherein the first cleanup hole diameterallows a first standard fastener to be inserted through the cleanuphole.
 4. The method of claim 2, wherein the step of reaming theplurality of misaligned holes further comprises reaming the plurality ofmisaligned holes to form the cleanup hole having a second cleanup holediameter, wherein the second cleanup hole diameter allows a firstoversized fastener to be inserted through the cleanup hole.
 5. A methodfor forming aligned holes, the method comprising: inserting a step gageinto a gap defined by misaligned holes, the step gage including at leasta first section having a first diameter and a second section having asecond diameter smaller than the first diameter, the first diametercorresponding to a first cleanup hole diameter and the second diametercorresponding to a second cleanup hole diameter larger than the firstcleanup hole diameter; when the first section fits through the gap,determining that a virtual hole diameter of the misaligned holescorresponds to a first standard fastener diameter, wherein a firststandard fastener has the first standard fastener diameter; and when thefirst section does not fit through the gap and the second section doesfit through the gap: determining that the virtual hole diameter of thegap is smaller than the first standard fastener diameter; and using atapered reamer to form a second cleanup hole centered on a virtual holeassociated with the virtual hole diameter, wherein the diameter of thesecond cleanup hole allows a first oversized fastener to be insertedthrough the second cleanup hole.
 6. The method of claim 5, wherein thestep gage further includes a third section having a third diametersmaller than the second diameter and a fourth section having a fourthdiameter smaller than the third diameter, the third diametercorresponding to a third cleanup hole diameter larger than the secondcleanup hole diameter and the fourth diameter corresponding to a fourthcleanup hole diameter larger than the third cleanup hole diameter, themethod further comprising: when the third section fits through the gapand the first and second sections do not fit through the gap:determining that the virtual hole diameter of the gap defined by themisaligned holes corresponds to a third cleanup hole diameter; using thetapered reamer to form an initial cleanup hole having the diameter ofthe second cleanup hole centered on the virtual hole associated with thevirtual hole diameter; and using a first standard reamer to form a thirdcleanup hole having the third cleanup hole diameter centered on thegeometric center of the initial cleanup hole, wherein the third cleanuphole diameter allows a second oversized fastener to be inserted throughthe third cleanup hole; and when the fourth section fits through the gapand the first, second, and third sections do not fit through the gap:determining that the virtual hole diameter of the gap corresponds to afourth cleanup hole diameter; determining that a fourth cleanup holehaving the fourth cleanup hole diameter centered on the virtual holeassociated with the virtual hole diameter is appropriate, wherein thefourth cleanup hole diameter allows a second standard fastener to beinserted through the fourth cleanup hole.
 7. The method of claim 6,wherein upon determining that the fourth section fits within the gap andthat the first, second, and third sections do not: forming the fourthcleanup hole centered on the virtual hole associated with the virtualhole diameter.
 8. The method of claim 7, wherein the step of forming thefourth cleanup hole further comprises the steps of: using the taperedreamer to form an initial cleanup hole having the diameter of the secondcleanup hole centered on the virtual hole associated with the virtualhole diameter; using the first standard reamer to form the third cleanuphole having the third cleanup hole diameter centered on the geometriccenter of the initial cleanup hole using a second standard reamer toform the fourth cleanup hole having the fourth cleanup hole diametercentered on the geometric center of the third cleanup hole.
 9. Themethod of claim 7, wherein the step of forming the fourth cleanup holefurther comprises the step of: using a second standard reamer and a jigto form the fourth cleanup hole having the fourth cleanup hole diametercentered on the virtual hole associated with the virtual hole diameter.10. The method of claim 5, wherein the step of using a tapered reamerfurther comprises the step of centering the reamer on the misalignedholes without the use of a jig.
 11. A system for forming aligned holes,the system comprising: a step gage configured to be inserted through agap defined by misaligned holes to determine a diameter of a cleanuphole, said step gage comprising: a first section having a first diametercorresponding to a first cleanup hole diameter; and a second sectionhaving a second diameter corresponding to a second cleanup hole diameterlarger than the first cleanup hole diameter, the first and secondsections being connected and extend in series along a longitudinal axisof the step gage; and a tapered reamer having a longitudinal axis andconfigured such that the longitudinal axis aligns with a center of thecleanup hole when the tapered reamer is at least partially inserted intothe gap defined by the misaligned holes.
 12. The system of claim 11,wherein the step gage further comprises at least a third section and afourth section which correspond to a third cleanup hole diameter and afourth cleanup hole diameter, respectively.
 13. The system of claim 11,wherein said tapered reamer comprises a tapered diameter section havinga beginning diameter which is smaller than a final diameter, the tapereddiameter section tapering from the final diameter to the beginningdiameter at an angle of between about 0.5 degrees and about 1.0 degreesper side.
 14. A step gage comprising: a first section having a diameterequal to about twice a diameter of an intended hole, minus a diameter ofa first cleanup hole; and a second section having a diameter equal toabout twice the diameter of the intended hole, minus a diameter of asecond cleanup hole which is larger than the diameter of the firstcleanup hole, wherein said first section and said second section areconnected and extend in series along a longitudinal axis of the stepgage.
 15. The step gage of claim 14, wherein the diameter of the firstcleanup hole allows a first standard fastener to be inserted through thefirst cleanup hole.
 16. The step gage of claim 14, wherein the diameterof the second cleanup hole allows a first oversized fastener to beinserted through the second cleanup hole.
 17. The step gage of claim 14,further comprising: a third section having a diameter equal to abouttwice the diameter of the intended hole, minus a diameter of a thirdcleanup hole which is larger than the diameter of the second cleanuphole; and a fourth section having a diameter equal to about twice thediameter of the intended hole, minus a diameter of a fourth cleanup holewhich is larger than the third cleanup hole; and wherein the first,second, third, and fourth sections are connected and extend in seriesalong the longitudinal axis of the step gage.
 18. The step gage of claim17, wherein: the diameter of the intended hole is approximately equal tothe diameter of the first cleanup hole; the diameter of the secondcleanup hole allows a first oversized fastener to be inserted throughthe second cleanup hole; the diameter of the third cleanup hole allows asecond oversized fastener to be inserted through the third cleanup hole;and the diameter of the fourth cleanup hole allows a second standardfastener to be inserted through the fourth cleanup hole
 19. The stepgage of claim 17, wherein the first section is positioned at a first endof the step gage, the second section is positioned between the first andthird sections, the third section is positioned between the second andfourth sections, and the fourth section is positioned at a secondopposing end of the step gage.
 20. The step gage of claim 14, whereinthe first and second sections are integrally formed.